Bevel Box Seals
Bevel Box Seals
• The bevel box is mostly removed to replace the gaskets. Refer to => [ Bevel Box Overview ] Description and Operation. When doing this, examine all the seals closely and replace any faulty ones.
Special tools, testers and auxiliary items required
• Slide Hammer-Complete Set (VW 771)
• Additional Part for VW 771 (VW 771/37)
• Pulling Hook (T20143)
• Thrust Piece (T10143)
• Thrust Piece (T10379)
• Thrust Piece (T10380)
• Grease Cap Puller (VW 637/2)
Left Seals, between Bevel Box and Transmission
• The seals (quantity: 2) can only be replaced when the bevel box is removed. Replace both seals.
Removing
- Remove the bevel box. Refer to the following:
Passat, Passat CC and CC, refer to => [ Bevel Box ] Removal and Replacement.
"Outer" Seal
- Pry out the seal using the pulling hook (T20143/2).
"Inner" Seal
• To prevent the new seal from being damaged later:
- Remove the circlip - 1 - from the flange shaft.
- Carefully remove the flange shaft - 2 - using a plastic hammer in the - direction of the arrow -.
- Remove the flange shaft seal on the transmission side.
Installing
"Outer" Seal
- Fill the space of the new seal between the sealing and dust lips - arrow - halfway with sealing grease for seal (G 052 128 A1).
- Lightly oil the new seal on the outer circumference.
- Install the seal until seated using the thrust piece (T10379).
"Inner" Seal
- Fill the space of the new seal between the sealing and dust lips - arrow - halfway with sealing grease for seal (G 052 128 A1).
- Lightly oil the new seal on the outer circumference.
- Install the seal until seated using the thrust piece (T10379).
- Carefully drive the flange shaft in as far as the stop using a plastic hammer.
- Install a new circlip - 1 - on the flange shaft.
- Install the bevel box. Refer to one of the following:
Passat, Passat CC and CC, refer to => [ Bevel Box ] Removal and Replacement.
- Check the gear oil in the bevel box. Refer to => [ Bevel Box Gear Oil, Checking and Filling ] Procedures.
Right Seal, Drive Axle Side
• The seal can be replaced with the bevel box still installed.
Removing
- Lift the vehicle.
- Remove the noise insulation under the engine/transmission. Refer to one of the following:
Passat and Tiguan
Passat CC and CC
- Remove the right drive axle.
• On some bevel boxes, a protective cap - arrow - is installed on the right. Replace the cap each time it is removed.
Remove the protective cap.
- Mount the grease cap puller (VW 637/2) in the recess - arrow - and pry off the cap.
- Remove the circlip - 1 - and seal - 2 - from the flange shaft.
- Place a drip tray under the bevel box.
Pry out the seal.
Installing
- Fill the space of new seal between the sealing and dust lips - arrow - halfway with sealing grease for seal (G 052 128 A1).
- Lightly oil the new seal on the outer circumference.
- Install the seal all the way.
- Install a new circlip and new seal on the flange shaft.
Bevel box with cap
- Install the new cap.
- Check the gear oil level in the bevel box. Refer to => [ Bevel Box Gear Oil, Checking and Filling ] Procedures.
- Install the drive axle.
Output Flange Seal, Bevel Box Removed
• The gasket can only be replaced when the bevel box is removed.
Special tools, testers and auxiliary items required
• Holding Fixture (VW 313)
• Tube 42 mm Dia. (VW 516)
• Thrust Piece (40-105)
• Thrust Piece (T10049)
• Gearbox Support (T10108)
• Stop Plate (T10108/1)
• Torque Wrench (V.A.G 1601)
• 2-Arm Puller (Kukko 20/10)
• 3-Arm Puller (Kukko 45-2)
• Slide Hammer-Complete Set (VW 771)
• Additional Part for VW 771 (VW 771/37)
• Sealing Grease for Seal (G 052 128 A1)
• 2 M10 x 30 Bolts
• 2 M12 x 10 Nuts
Removing
- Remove the bevel box. Refer to the following:
Passat, Passat CC and CC, refer to => [ Bevel Box ] Removal and Replacement.
- Mount the bevel box on the hole marked with the number - 5 - - arrow - in the gearbox support (T10108).
A Insert M12 x 10 nuts (quantity: 4) between the bevel box and gearbox support. The nuts act as spacers.
- Align the bevel box to the hole that is opposite it and secure.
- Place the drip tray for VAS 6100 (VAS 6208) below.
- Drain the gear oil from the bevel box.
- Secure the bevel box output flange using the stop plate (T10108/1) and install the M10 x 30 bolts - arrows -.
- Remove the nut from the output flange.
A Socket attachment SW 36 for 3/4 inch drive
- Pivot the bevel box so that the output shaft faces upward.
- Remove the output shaft from the bevel box shaft bevel gear.
A 3-arm puller, for example, 3-arm puller (Kukko 45-2)
- Remove the output shaft seal - A -.
- Clean any locking fluid residue from the threads on the shaft bevel gear.
Installing
- Install the new seal using the thrust piece (T10049).
- Fill the space between the sealing and dust lips half way with sealing grease for seal (G 052 128 A1).
- Pull in the output flange using a 2-arm puller - A -.
A 2-arm puller, for example, 2-arm puller (Kukko 20/10)
- Position the pulling hook on the underside of the drive pinion housing.
- Coat the threads of the new nut with liquid locking fluid (D 000 600).
- Tighten the new output flange nut to specification, see - item 11 - in the => [ Bevel Box Overview ] Description and Operation.
A Socket attachment SW 36 for 3/4 inch drive
- Install the bevel box. Refer to one of the following:
Passat, Passat CC and CC, refer to => [ Bevel Box ] Removal and Replacement.
- Check the gear oil level in the bevel box. Refer to => [ Bevel Box Gear Oil, Checking and Filling ] Procedures.